Method of making silver-containing dispersions with nitrogenous bases

ABSTRACT

A method is used to prepare silver nanoparticle cellulosic polymer composites. A cellulosic polymer, reducible silver ions in an amount of a weight ratio to the cellulosic polymer of 5:1 to 50:1, and an organic solvent are mixed. Each organic solvent has a boiling point at atmospheric pressure of 100° C. to 500° C. The Hansen parameter (δ T   Polymer ) of the cellulosic polymer is less than or equal to the Hansen parameter (δ T   Solvent ) of the organic solvent. The resulting premix solution is heated to at least 75° C., and a (d) nitrogenous base is added to provide a concentration of the nitrogenous base in an equimolar amount or in molar excess in relation to the amount of reducible silver ions, thereby forming a silver nanoparticle cellulosic polymer composite. After cooling, the silver nanoparticle cellulosic polymer composite is isolated and re-dispersed in an organic solvent to provide a non-aqueous silver-containing dispersion.

CROSS-REFERENCE TO RELATED APPLICATIONS

Reference is made to the following commonly assigned and copendingpatent application, the disclosures of all of which are incorporatedherein by reference:

U.S. Ser. No. 15/456,686, filed Mar. 13, 2017 by Shukla and Donovan;

U.S. Ser. No. 15/456,827, filed Mar. 13, 2017 by Shukla, Donovan, andGillmor;

U.S. Ser. No. 15/456,868, filed Mar. 13, 2017 by Shukla and Donovan;

U.S. Ser. No. 15/______ (filed on even date herewith by Shukla andDonovan) and entitled “Silver-containing Non-Aqueous CompositionsContaining Cellulosic Polymers” (Attorney Docket K002183/JLT);

U.S. Ser. No. 15/______ (filed on even date herewith by Shukla, Donovan,and Klubek) and entitled “Method of Making Silver-containing Dispersion”(Attorney Docket K002190/JLT); and

U.S. Ser. No. 15/______ (filed on even date herewith by Shukla andDonovan) and entitled “Non-Aqueous Silver-containing Dispersions”(Attorney Docket K002192/JLT).

FIELD OF THE INVENTION

This invention relates to a method for forming a non-aqueous dispersionof a silver nanoparticle composite by mixing a cellulosic polymer, ahydroxylic solvent, and reducible silver ions, to which a nitrogenousbase is introduced, to form a silver nanoparticle composite. Aftercooling and isolation, the silver nanoparticle composite is re-dispersedin one or more organic solvents for future use, for example as an “ink”to form electrically-conductive articles.

BACKGROUND OF THE INVENTION

It is well known that silver has desirable electrical and thermalconductivity, catalytic properties, and antimicrobial behavior. Thus,silver and silver-containing compounds have been widely used in alloys,metal plating processes, electronic devices, imaging sciences, medicine,clothing or other fibrous materials, and other commercial and industrialarticles and processes to take advantage of silver's beneficialproperties.

For example, silver compounds or silver metal have been described foruse as metallic patterns or electrodes in metal wiring patterns, printedcircuit boards (PCB's), flexible printed circuit boards (FPC's),antennas for radio frequency identification (RFID) tags, plasma displaypanels (PDP's), liquid crystal displays (LCD's), organic light emittingdiodes (OLED's), flexible displays, and organic thin film transistors(OTFT's), among other electronic devices known in the art.

Rapid advances are also occurring for making and using variouselectronic devices for communication, financial, and archival purposes.

Silver is an ideal conductor having electrical conductivity 50 to 100times greater than indium tin oxide that is commonly used today in manydevices. For example, the art has described the preparation ofelectrically-conductive films by forming and developing (reducing) asilver halide image in “photographic” silver halide emulsions through anappropriate mask to form electrically-conductive grid networks havingsilver wires having average sizes (width and height) of less than 10 μmand having appropriate lengths.

While silver as an electrical conductor has a wide range of potentialuses in the field of printed electronics, the microfabrication ofelectrically-conductive tracks (grids, wires, or patterns) byphotolithographic and electroless techniques is time consuming andexpensive, and there is an industrial need for direct digital printingto simplify the processes and to reduce manufacturing costs.

Furthermore, it is desirable to fabricate silver-containing electronicsonto polymeric or similar temperature-sensitive substrates bysolution-based printing processes. Metallic electrically-conductivewires or grids of low resistance must be achieved at sufficiently lowtemperatures to be compatible with organic electronics on polymericsubstrates. Among various known methods for fabricatingelectrically-conductive silver grids or patterns, the direct printing ofsilver-containing inks provides attractive prospects for making suchelectrically-conductive patterns.

Inkjet printing and flexographic printing have also been proposed forproviding patterns of silver or silver-containing compounds, requiringthe careful fabrication of a silver-containing paste or “ink” withdesirable surface tension, viscosity, stability, and other physicalproperties required for such application processes. High silver contenthas generally been required for high electrical conductivity, andcalcination or sintering may be additionally required for increasingelectrical conductivity of printed silver inks.

Some approaches to providing silver metal is to employ a chemical inkformulation where the silver source is a molecular precursor or cation(such as a silver salt) that is then chemically reacted (or reduced) toproduce silver metal. Electrically-conductive inks that are in the formof a chemical solution rather than as a suspension or dispersion ofmetal particles, have gained interest in recent years. One conductiveink of this type is known as a Metalorganic Decomposition (MOD) varietyink, for example, as described by Jahn et al. [Chem. Mater. 22,3067-3071 (2010)] who investigated silver printing using an aqueoustransition metal complex [AgO₂C(CH₂OCH₂)₃H]-containing MOD ink. Theyreported the formation of metallic silver features having electricalconductivities as high as 2.7×10⁷ S m⁻¹, which corresponds to anelectrical conductivity that is 43% of that of bulk silver, although asintering temperature of 250° C. was required.

U.S. Patent Application Publication 2015/0004325 (Walker et al.)

describes a chemically-reactive silver ink composition comprised of acomplex of a silver carboxylate salt and an alkylamine, in which thecomplex is used to form an electrically-conductive silver structure at atemperature of 120° C. or less. Unfortunately, even these temperaturesrender the ink incompatible with many polymeric and paper substratesused in flexible electronic and biomedical devices. Furthermore, sincealkylamines are known to reduce silver at room temperature, long termstability of such compositions is tentative. Furthermore, thepublication teaches long heating times were needed to obtain lowresistivity in the resulting articles.

Other industrial approaches to preparing electrically-conductive filmsor elements have been directed to formulating and applying photocurablecompositions containing dispersions of metal particles such as silvermetal particles to substrates, followed by curing the photocurablecomponents in the photocurable compositions. The applied silverparticles in the cured compositions can act as catalytic (seed)particles for electrolessly plated electrically-conductive metals.Useful electrically-conductive grids prepared in this manner aredescribed for example, in U.S. Pat. Nos. 9,188,861 (Shukla et al.) and9,207,533 (Shukla et al.) and in US Patent Application Publications2014/0071356 (Petcavich) and 2015/0125596 (Ramakrishnan et al.). Usingthese methods, photocurable compositions containing catalytic silverparticles can be printed and cured on a suitable transparent substrate,for example, a continuous roll of a transparent polyester film, and thenelectroless metal plating can be carried out on the catalytic silverparticles. However, these methods require that high quantities ofpurchased silver particles be uniformly dispersed within thephotocurable compositions so that coatings or printed patterns have asufficiently high concentration of catalytic sites. Without effectivedispersing, silver particles readily agglomerate, leading to lessineffective electroless plating and electrical conductivity.

Moreover, forming stable patterns of silver particles in this mannerrequires the presence of photosensitive components such as polymerizablemonomers or cross-linkable polymers that must be exposed to suitableradiation. Scaling such curing procedures to high volume use can bedifficult and hard to reproduce on a consistent scale, especially toproduce fine line electrically-conductive meshes or grids where theuniformity and size of fine lines are subjected to highly rigorousstandards.

Efforts are being directed in the industry to avoid the need forphotocuring. For, example, U.S. Patent Application Publication2012/0225126 (Geckeler et al.) describes a solid-state method forpreparing silver nanoparticles using a mixture of a silver salt and awater-soluble polymer such as a starch or cellulose derivative that actsas a silver ion reducing agent. The mixture is milled by a high-speedvibration milling process to form silver nanoparticles within thewater-soluble starch or cellulosic polymer so that a solvent is notneeded for synthesis or transportation of the silver nanoparticles.

Various methods have been employed in the production of silvernanoparticles, such as co-precipitation methods in an aqueous solution,electrochemical methods, aerosol methods, reverse microemulsion methods,chemical liquid deposition methods, photochemical reduction methods,chemical reduction methods in a solution and UV irradiation methods.However, the conventional technologies have difficulties in the controlof particle sizes and large-scale production of particles.

There are a variety of methods for producing nanometer-sized metallicnanoparticles. For example, U.S. Pat. 6,572,673 (Lee et al.) discloses aprocess for preparing metal nanoparticles, comprising reacting suitablemetal salts and anionic surfactant containing an anionic group such as acarboxylic group, sulfate group, or sulfonate group as reducing agent inwater under reflux at a temperature of 50-140° C. Such processes arecarried out in aqueous solutions.

U.S. Pat. No. 9,005,663 (Raghuraman et al.) discloses a method formaking silver nanoparticles, comprising reacting a silver salt with aphosphene amino acid. However, the phosphene amino acid reactant is anexpensive material.

U.S. Pat. No. 7,892,317 (Nia) discloses a process for the synthesis ofsilver nano particle, consisting of reacting silver salt and an anionicsurfactant, or a nonionic surfactant, and a reducing agent in an aqueoussolution at room temperature.

U.S. Pat. No. 9,496,068 (Kurihara et al.) discloses a process for thesynthesis of amine coated silver nano particles via thermaldecomposition of oxalate ion-alkylamine-alkyl diamine-silver complex.

U.S. Patent Application Publication 2010/0040863 (Li) discloses aprocess for producing carboxylic acid-stabilized silver nanoparticles byheating a mixture of a silver salt long alkyl chain carboxylic acid anda tertiary amine in methanol.

U.S. Patent Application Publication 2014/0312284 (Liu et al.) disclosesa process for producing an organoamine stabilized silver nanoparticle byreduction of silver salts with hydrazine in methanol. However, hydrazineis a toxic material and it would not be desirable to include it in amanufacturing process.

Cellulose is a polydisperse linear homopolymer consisting ofregioselective and enantioselective β-1,4-glycosidic linked D-glucoseunits. The homopolymer contains three reactive hydroxyl groups at theC-2, C-3 and C-6 atoms that are in general, accessible to the typicalchemical conversions of primary and secondary —OH groups.

The use of cellulose together with its derivatives has wide spreadapplications, for example in fibers, films, plastics, coatings,suspension agents, composites. With the advent of synthetic polymers,their uses have somewhat diminished, but cellulose derivatives are stillthe raw materials of choice for some uses. In addition, various studiesare on-going to look for and expand their use in existing and newtechnologies. Cellulosic polymers can be considered renewable resourcesin some instances. An inherent problem that faces users of cellulosicpolymers is their general insolubility in most common solvents.Modifying the structure of cellulosic polymers can improve theirsolubility, leading to the synthesis of various cellulose derivatives(cellulosics) that come in all forms and structures depending on thefunctional group(s) used in place of the hydroxyl groups on thecellulose chain.

For example, cellulose derivatization can involve partial or fullesterification or etherification of the hydroxyl groups on the cellulosechain by reaction with various reagents to afford cellulose derivativeslike cellulose esters and cellulose ethers. Among all cellulosederivatives, cellulose acetate is recognized as the most importantorganic ester of cellulose owing to its extensive industrial andcommercial importance. Properties of cellulose derivatives (esters andethers) are determined primarily by the functional group. However, theycan be modified significantly by adjusting the degree offunctionalization and the degree of polymerization of the polymerbackbone to modify solubility in various solvents.

The solution properties of cellulose acetates have been well studied andhave been shown to be influenced by the average degree of substitutionand the distribution of substituents along the chain. Previous work onthe gelation mechanism of cellulose acetate has shown interestingbehavior with respect to the sol-gel transition. Cellulose acetate gelsexhibit thermally reversible properties that depend on factors such asconcentration, acetyl content, and the type of solvent. It is usuallydifficult to predict if cellulose will gel in a given organic solvent,and in most cellulose acetate/solvent systems, gelation occurs after thesolution is heated to a specific temperature and subsequently cooled.For example, Kwon et al., Bull. Korean Chem. Soc. 26(5), 837-840describe a study of silver nanoparticles in cellulose acetate solutions.

U.S. Ser. No. 15/456,686 (noted above) describes a method for preparingarticles using silver nanoparticles that are obtained by thermalreduction of reducible silver ions in the presence of certain cellulosicpolymers.

Despite all the various approaches and efforts to provideelectrically-conductive silver in various consumer and industrialarticles described above, there remains a need for simpler and lessexpensive compositions and methods for generation of silvernanoparticles in a fashion suitable particularly for pattern formationin high speed manufacturing processes.

Although, as described above, a number of methods to make silvernanoparticles and compositions containing them are known, a number ofchallenges remain which need to be addressed before such compositionscan be used in printed electronic applications. For example, thereremains a need for an expeditious method of making silver nanoparticlesthat doesn't require toxic reagents and solvents; for dispersing agentsthat are inexpensive and environmentally benign; for a method for largescale manufacturing and storage of silver nanoparticles; and for anefficient way of re-dispersibility of manufactured silver nanoparticlesin environmentally friendly solvents.

SUMMARY OF THE INVENTION

The present invention provides a method comprising, in sequence:

-   A) mixing:

(a) one or more polymers selected from one or more of cellulose acetate,cellulose acetate phthalate, cellulose acetate butyrate, celluloseacetate propionate, cellulose acetate trimellitate, hydroxypropylmethylcellulose phthalate, methyl cellulose, ethyl cellulose, hydroxyethylcellulose, hydroxypropylmethyl cellulose, and carboxymethyl cellulose;

(b) reducible silver ions present in an amount of a weight ratio of (b)reducible silver ions to the one or more (a) polymers of at least 5:1and up to and including 50:1; and

(c) one or more organic solvents, each of which has a boiling point atatmospheric pressure of at least 100° C. and up to but less than 500°C., wherein the Hansen parameter (δ_(T) ^(Polymer)) of each of the oneor more polymers is less than or equal to the Hansen parameter (δ_(T)^(Solvent)) of each of the one or more organic solvents,

to form a premix solution;

-   B) heating the premix solution to a temperature of at least 75° C.;-   C) while keeping the premix solution at the temperature of at least    75° C., adding a (d) nitrogenous base having a pKa in acetonitrile    of at least 15 and up to and including 25 at 25° C., to provide a    concentration of the (d) nitrogenous base in an equimolar amount or    in molar excess in relation to the amount of (b) reducible silver    ions,

to form a silver nanoparticle composite;

-   D) after cooling, isolating the silver nanoparticle composite; and-   E) re-dispersing the silver nanoparticle composite in the same or    different one or more (c) organic solvents used in A), to provide a    non-aqueous silver-containing dispersion comprising the silver    nanoparticle composite.

In some embodiments, the method can further comprise:

-   disposing the non-aqueous silver-containing dispersion onto a    substrate, and-   removing the same or different one or more (c) organic solvents.

The present invention provides a simple, safe, and inexpensive way togenerate a non-aqueous dispersion of silver nanoparticles from anon-aqueous silver precursor composition comprising reducible silverions, a cellulosic polymer, and a nitrogenous base. The method accordingto this invention can be readily and safely carried out formanufacturing high weight fraction, fully dispersed silver nanoparticlesthat have long term stability as the silver nanoparticles do not readilyagglomerate in the relatively benign organic solvents. These silvernanoparticle-containing compositions can be easily deposited or formedinto patterns for various uses.

The present invention provides these advantages by means of using anitrogenous base to facilitate faster silver ion reduction in thepresence of the cellulosic polymer. The cellulosic polymers and organicsolvents used in the non-aqueous silver precursor compositions alsofacilitate silver ion reduction and provide physical stability of theresulting silver nanoparticles using inexpensive and environmentallysafe dispersing agents. The inventive compositions and methods can thusbe used to provide compositions or dispersions of silver nanoparticlesthat can be used in various ways, for example, as applied to a substratein a pattern for further processing.

Other advantages of the present invention would be readily apparent toone skilled in the art in view of the teaching provided herein.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a graphical representation of particle size distribution asdescribed below in Invention Example 1.

FIG. 2 is a graphical representation of particle size distribution asdescribed below in Invention Example 2.

FIG. 3 is a graphical representation of chemical analysis of the silvernanoparticles-cellulose polymer composite prepared in Invention Example2 below.

FIG. 4 is a graphical representation of particle size distribution asdescribed below in Invention Example 3.

DETAILED DESCRIPTION OF THE INVENTION

The following discussion is directed to various embodiments of thepresent invention and while some embodiments can be desirable forspecific uses, the disclosed embodiments should not be interpreted orotherwise considered be limit the scope of the present invention, asclaimed below. In addition, one skilled in the art will understand thatthe following disclosure has broader application than is explicitlydescribed and the discussion of any embodiment.

Definitions

As used herein to define various components of the non-aqueous silverprecursor composition, unless otherwise indicated, the singular forms“a,” “an,” and “the” are intended to include one or more of thecomponents (that is, including plurality referents).

Each term that is not explicitly defined in the present application isto be understood to have a meaning that is commonly accepted by thoseskilled in the art. If the construction of a term would render itmeaningless or essentially meaningless in its context, the termdefinition should be taken from a standard dictionary.

The use of numerical values in the various ranges specified herein,unless otherwise expressly indicated otherwise, are approximations asthough the minimum and maximum values within the stated ranges were bothpreceded by the word “about.” In this manner, slight variations aboveand below the stated ranges can be used to achieve substantially thesame results as the values within the ranges. In addition, thedisclosure of these ranges is intended as a continuous range includingevery value between the minimum and maximum values.

Unless otherwise indicated, the term “weight %” refers to the amount ofa component or material based on the total amount of a non-aqueoussilver precursor composition or non-aqueous dispersion. In otherembodiments, “weight %” can refer to the % solids (or dry weight) of adry layer, coating, thin film, or silver-containing pattern.

Unless otherwise indicated, the term “non-aqueous” as applied to thecompositions and dispersions according to the present invention meansthat solvent media used to form such compositions are predominantlyorganic in nature and water is not purposely added but may be present inan amount of less than 10 weight % by virtue of being part of a chemicalcomponent, or particularly less than 5 weight %, or even less than 1weight %, of the total weight of all solvents in the composition.

Unless otherwise indicated, the term “non-aqueous silver precursorcomposition” means that the silver present therein is predominantly(greater than 50 weight % of total silver) in the form of reduciblesilver ions.

The average dry thickness of silver nanoparticle-containing lines, gridlines, or other pattern features described herein can be the average ofat least 2 separate measurements taken, for example, using electronmicroscopy, optical microscopy, or profilometry all of which shouldprovide substantially the same results for the same test sample.

The use of “dry” in reference to thickness and width of lines, patterns,or layers, refers to embodiments in which at least 80 weight % oforiginally present organic solvent(s) has been removed.

As used herein for defining silver nanoparticles, “mean particle size”is measured using dynamic light scattering (DLS), that is sometimesreferred to as Quasi-Elastic Light Scattering (QELS), and is awell-established technique for measuring the size and size distributionof molecules and particles typically in the submicron region, and evenlower than 1 nm. Commercial DLS instruments are available from, forexample, Malvern and Horiba who also supply instructions for use of suchequipment, and such equipment and accompany instructions can be used tocharacterize and carry out the present invention.

The boiling point of organic solvents described herein can be determinedfrom known publications or measured using standard methods.

Unless otherwise indicated herein, viscosity can be determined at 25° C.using any standard commercially available viscometer.

Unless otherwise indicated, the term “group” particularly when used todefine a substituent or a moiety, can itself be substituted orunsubstituted (for example an “alkyl group” refers to a substituted orunsubstituted alkyl group) by replacement of one or more hydrogen atomswith suitable substituents (noted below) such as a fluorine atom.Generally, unless otherwise specifically stated, substituents on any“groups” referenced herein or where something is stated to be possiblysubstituted, include the possibility of any groups, whether substitutedor unsubstituted, which do not destroy properties necessary for theutility of the component or non-aqueous silver precursor composition. Itwill also be understood for this disclosure and claims that reference toa compound or complex of a general structure includes those compounds ofother more specific formula that fall within the general structuraldefinition. Examples of substituents on any of the mentioned groups caninclude known substituents such as halogen (for example, chloro andfluoro); alkoxy, particularly those with 1 to 5 carbon atoms (forexample, methoxy and ethoxy); substituted or unsubstituted alkyl groups,particularly lower alkyl groups (for example, methyl andtrifluoromethyl), particularly either of those having 1 to 6 carbonatoms (for example, methyl, ethyl, and t-butyl); and other substituentsthat would be readily apparent in the art.

Unless otherwise indicated, the terms “total Hansen solubilityparameter” and “total Hansen parameter” refer to the same thing. HansenSolubility Parameters (also named reverse solvency principle) weredeveloped by Charles Hansen as a way of predicting if one material willdissolve in another and form a solution. They are based on the conceptthat “like dissolves like” where one molecule is defined as being “like”another if it bonds to itself in a similar way. Each chemical moleculeis given three Hansen parameters, each generally measured inMpa^(0.5):δ_(d) the energy from dispersion bonds between molecules;δ_(p), the energy from polar bonds between molecules; and δ_(h), theenergy from hydrogen bonds between molecules. The “total Hansensolubility parameter” is defined as:

δ²=δ_(d) ²+δ_(p) ²+δ_(h) ²

These three Hansen parameters can be treated as co-ordinates for a pointin three dimensions also known as the Hansen space. The nearer that twomolecules are in this three dimensional space, the more likely they areto dissolve into each other. To determine if the total Hansen parametersof two molecules (usually a solvent and a polymer) are within range. avalue called the interaction radius (R₀) is given to the substance beingdissolved. This interaction radius determines the radius of the spherein the Hansen space and its center is the three Hansen parameters. Inorder to calculate the distance (Ra) between the Hansen parameters inthe Hansen space the following formula is used:

R _(a) ²=4(δ_(d1)−δ_(d2))²+(δ_(p1)−δ_(p2))²+(δ_(h1)−δ_(h2))²

The concept of a total Hansen parameter is well understood by anyoneskilled in the art. A detailed description of the derivation and theoryis found in various references such as (1) A. F. M. Barton, “Handbook ofPolymer-Liquid Interaction Parameters and Solubility Parameters,” CRCPress Inc. (1990) and (2) Solubility Parameter Values, Eric A. Grulke,Polymer Handbook, John Wiley and Sons, Inc. (1989). In many instances,the total Hansen parameter of each useful polymer can be obtained fromproduct literature where available, estimated from studies of similarmaterials as published in the Handbook of Polymer-Liquid InteractionParameters and Solubility Parameters, by Allan F. M. Barton, CRC Press(1990), or determined by solubility studies. The total Hansen parametersof organic solvent mixtures can be calculated using the sum of volumefractions of the individual organic solvent components in the premixsolution. Total Hansen parameters as well as the three-component Hansenparameters for dispersive, polar, and hydrogen-bonding components of thesolubility parameter, are readily available in the literature.

Uses

The deposition or patterning of functional electrodes, pixel pads, andconductive traces, lines, and tracks, that meets electricalconductivity, processing, and cost requirements for practicalapplications has been a great challenge. Silver metal is of interest inthe preparation of electrically-conductive elements for use inelectronic devices with or without further electroless plating.

The non-aqueous silver-containing dispersions described herein can beused for forming metallic silver patterns and electrodes for example inmembrane touch switches (MTS), battery testers, biomedical,electroluminescent lamps, radio frequency identification (RFID) antenna,flat panel displays such as plasma display panel (PDP) and organic lightemitting diode (OLED) displays, printed transistors and thin filmphotovoltaics, and thereby reduce the number of steps for patternformation in such devices.

The non-aqueous silver precursor compositions described herein haveactual and potential uses in various technologies and industries. Mostspecifically, they can be used to provide silver metal for variouspurposes, including but not limited to, the formation ofelectrically-conductive grids or patterns of fine wires or othergeometric forms, the formation of silver seed particles for electrolessplating with other electrically-conductive metals, and the formation ofsilver in various materials for antimicrobial activity.

More specifically, the non-aqueous silver precursor compositionsaccording to the present invention are useful to provide silver metal innon-aqueous dispersions that in turn can be used to provideelectrically-conductive metal patterns. These electrically-conductivemetal patterns can be incorporated into various devices including butnot limited to, touch screens or other transparent display devices, andin modern electronics such as solar cell electrodes, electrodes inorganic thin film transistors (OTFTs), flexible displays, radiofrequency identification tags, light antennas, and other devices thatwould be readily apparent to one skilled in the art.

Non-Aqueous Silver Precursor Compositions

For all embodiments, the non-aqueous silver precursor compositionsaccording to the present invention contain four essential components forpurposes of providing silver metal in the form of silver nanoparticlesaccording to the present invention: one or more (a) polymers (such asone or more cellulosic polymers) as described below; (b) reduciblesilver ions in the form of one or more silver salts or silver complexesas described below; an organic solvent medium consisting of (c) or moreorganic solvents, as described below; and (d) one or more nitrogenousbases, as described below. No other components are purposely added tothe non-aqueous silver precursor compositions according to the presentinvention to achieve the inventive advantages or purposes, and as notedabove, water is not purposely included. As described below, for someembodiments, (e) carbon black can be present as a fifth essentialcomponent.

Upon thermal treatment, as described below, the non-aqueous silverprecursor composition according to this invention can be converted intoa corresponding non-aqueous dispersion or non-aqueous silver-containingdispersion comprising a silver nanoparticle composite comprising bothsilver and one or more polymers as described below. It is desirable thatat least 90 mol %, at least 95 mol %, or even at least 98 mol % (whichmeans “substantially all”) of the (b) reducible silver ions areconverted to silver during this process.

The one or more (a) polymers, (b) reducible silver ions, (c) organicsolvents, and nitrogenous bases can be combined in general by mixingthem under suitable ambient conditions so that thermal reduction doesnot occur prematurely to any appreciable extent. In some embodiments,the (a), (c), and (d) components can be formulated or mixed to form apremix solution and under appropriate heating, the (b) reducible silverions can be added the premix solution in a controlled fashion.Alternatively, the (a), (b), and (c) components can be formulated ormixed to form a premix solution, and the (d) nitrogenous base can beadded to the premix solution in a controlled fashion. Details of thesemethods are described below.

Ultimately, the non-aqueous silver precursor composition is formed, andit generally has a % solids of at least 1% and up to and including 50%,or more typically of at least 5% and up to and including 20%. The amountof solids, and (c) organic solvents, and viscosity, can thus be adjustedfor a particular use or silver ion reduction operation.

The non-aqueous silver precursor composition is generally in liquid formhaving a viscosity of at least 1 centipoise (0.001 Pascal sec) and up toand including 5,000 centipoise (5 Pascal sec), or more likely aviscosity of at least 3 centipoise (0.003 Pascal sec) and up to andincluding 50 centipoise (0.05 Pascal sec), all measured at 25° C.

The non-aqueous (silver-containing) dispersion described below can havethe same or different viscosity as the corresponding non-aqueous silverprecursor composition. In most embodiments, the two compositions haveessentially the same viscosity, that is, no more than 10% difference.

(a) Polymers:

The polymers useful in the practice of the present invention are organicin nature and can be used singly or in mixtures of two or more differentmaterials. When used in mixtures, the two or more different materialscan be present in the same or different amounts within the total polymeramount. Both cellulose esters and cellulose ethers can be used in thepresent invention.

Representative useful polymers for the practice of the present inventionare selected from cellulose acetate, cellulose acetate phthalate,cellulose acetate butyrate, cellulose acetate propionate, celluloseacetate trimellitate, hydroxypropylmethyl cellulose phthalate, methylcellulose, ethyl cellulose, hydroxyethyl cellulose, hydroxypropylmethylcellulose, carboxymethyl cellulose, and mixtures of two or more of suchmaterials.

Particularly useful polymers according to the present invention includecarboxymethyl cellulose, cellulose acetate butyrate, cellulose acetatepropionate, ethyl cellulose, and cellulose acetate, individually or inmixtures.

It can also be useful to use cellulosic polymers such as celluloseesters that comprise free hydroxy groups directly attached to thepolymer backbone to provide a free hydroxyl content in an amount of atleast 1%, or at least 2%, and up to and including 5%, based on the totalhydroxy groups that could potentially be present in the polymer. Theremaining hydroxy groups in the molecule would be esterified so thatthere is relatively low free hydroxyl content.

The one or more (a) polymers can be present in a total amount of atleast 1 weight % and up to and including 25 weight %, or more likely ofat least 3 weight % and up to and including 10 weight %, based on thetotal weight of silver in the non-aqueous silver precursor composition.

Each of the useful polymers can be readily obtained from variouscommercial sources, or in some cases, they can be prepared using knownstarting materials, reaction conditions, and known synthetic procedures.

(b) Reducible Silver Ions:

Reducible silver ions can be provided in the non-aqueous silverprecursor composition from many sources as long as each silver salt orsilver complex in which they are provided is soluble within the one ormore (c) hydroxylic organic solvents at an amount of at least 1 g/literat 20° C.

In general, silver salts or silver complexes comprised of reduciblesilver ions and any suitable organic or inorganic anion or complexedmoiety (or a combination of anions and complexed moieties) can be usedin the practice of the present invention to provide the (b) reduciblesilver ions for the present invention. Such silver complexes can bemononuclear, dinuclear, trinuclear, or higher and each compoundgenerally has a net neutral charge. The following classes of usefulreducible silver ion-containing salts and reducible silverion-containing complexes are described as representative materials, butthe present invention is not to be interpreted to be limited to them.Such reducible silver ion-containing materials can be readily purchasedfrom various commercial sources or prepared using known procedures,starting materials, and reaction conditions unless otherwise indicated.

(i) A first class of reducible silver ion-containing compounds aresilver salts having organic or inorganic anions. Some representativesilver salts include but not limited to, silver nitrate, silver acetate,silver benzoate, silver nitrite, silver thiocyanate, silver myristate,silver citrate, silver phenylacetate, silver malonate, silver succinate,silver adipate, silver phosphate, silver perchlorate, silveracetylacetonate, silver lactate, silver salicylate, silver oxalate,silver 2-phenylpyridine, silver trifluoroacetate; silver fluoride andsilver fluoride complexes such as silver (I) fluorosulfate, silver (I)trifluoromethane sulfate, silver (I) pentafluoropropionate, and silver(I) heptafluorobutyrate; β-carbonyl ketone silver (I) complexes; silverproteins; and derivatives of any of these materials.

(ii) Complexes of hindered aromatic N-heterocycle with (b) reduciblesilver ions can be used in the practice of this invention. The term“hindered” as used to define hindered aromatic N-heterocycle means thatthe moiety has a “bulky” group located in the a position to the nitrogenatom in the aromatic ring. Such bulky groups can be defined using theknown “A-value” parameter that is a numerical value used for thedetermination of the most stable orientation of atoms in a molecule(using conformational analysis) as well as a general representation ofsteric bulk. A-values are derived from energy measurements of amono-substituted cyclohexane ring. Substituents on a cyclohexane ringprefer to reside in the equatorial position to the axial. In the presentinvention, the useful “bulky” groups in the hindered aromaticN-heterocycle have an A-value of at least 0.05. Useful reducible silverion-containing complexes of this type are described in U.S. Pat. No.9,377,688 (Shukla), the disclosure of which is incorporated herein byreference for a further description of properties, representativecompounds, and methods for preparing them.

(iii) Other useful complexes comprise (b) reducible silver ions aresilver carboxylate-trialkyl, carboxylate-triaryl, andcarboxylate-alkylaryl phosphite complexes and mixtures of thesecompounds. The terms “carboxylate-trialkyl phosphite” and“carboxylate-triaryl phosphite” are to be interpreted herein asindicating that the complex of which it is a part can have three of thesame or different alkyl groups, or three of the same or different arylgroups, respectively.

The term “carboxylate-alkylaryl phosphite” refers to a compound having amixture of a total of three alkyl and aryl groups, in any combination.Useful reducible silver ion-containing complexes of this type aredescribed in U.S. Pat. No. 9,375,704 (Shukla), the disclosure of whichis incorporated herein by reference for a further description ofproperties, representative compounds, and methods for preparing them.

(iv) Silver-oxime complexes can be used to provide (b) reducible silverions, and these materials are generally non-polymeric in nature (meaningthat the silver complex molecular weight is less than 3,000). Usefulnon-polymeric silver-oxime complexes of this type are described in U.S.Pat. No. 9,387,460 (Shukla), the disclosure of which is incorporatedherein by reference for a further description of properties,representative compounds, and methods for preparing them.

(v) Other useful silver complexes comprising (b) reducible silver ionscan be represented by the following Structure (V):

wherein L represents an α-oxy carboxylate; P represents a 5- or6-membered N-heteroaromatic compound; a is 1 or 2; b is 1 or 2; and c is1, 2, 3, or 4, provided that when a is 1, b is 1, and when a is 2, b is2.

Each of the complexes of Structure (V) comprises one or two reduciblesilver ions. Each reducible silver ion is complexed with one or twoα-oxy carboxylate compounds that can be via two oxygen atoms providedfrom the same molecule of an α-oxy carboxylate compound, or oxygen atomsprovided from two molecules of the same or different α-oxy carboxylatecompounds.

The α-oxy carboxylate groups (moieties or components) can be defined inwhich the α-carbon atom attached directly to the carboxyl group[—C(═O)O—] has a hydroxy group, oxy, or an oxyalkyl substituent group.Thus, the α-oxy carboxylates can be either α-hydroxy carboxylates,α-alkoxy carboxylates, or α-oxy carboxylates. With the α-hydroxycarboxylates and α-alkoxy carboxylates, the remainder of the valences ofthat α-carbon atom can be filled with hydrogen or a branched or linearalkyl group (substituted or unsubstituted) as described below in moredetail. In addition, the α-oxy carboxylate (L) generally has a molecularweight of 250 or less, or 150 or less.

In Structure (V) shown above, b is 1 or 2, and in the embodiments whereb is 2, the two α-oxy carboxylate compounds within a single complexmolecule can be the same or different compounds. In some embodiments ofthe present invention, L of Structure (V) described above can berepresented by the following Structure (VI):

wherein R₁, R₂, and R₃ are independently hydrogen or branched or linearalkyl groups. In most embodiments, at least one of R₁ through R₃ is abranched or linear alkyl group having from 1 to 8 carbon atoms, and anyof the hydrogen atoms in such branched or linear alkyl groups can bereplaced with a heteroatom such as a fluorine atom substituent.

Some particularly useful conjugate acids from which α-oxy carboxylates(L) of Structure (VI) can be selected from the group consisting oflactic acid, 2-hydroxybutyric acid, 2-hydroxy-3-methylbutyric acid,2-hydroxy-3,3-dimethylbutyric acid, 2-hydroxy-isobutyric acid,2-hydroxy-2-methylbutyric acid, 2-ethyl-2-hydroxybutyric acid,2-hydroxy-2,3-dimethylbutyric acid, 2-ethyl-2-methoxybutyric acid,2-methoxy-2-methylpropanoic acid, 1-hydroxycyclopentane-1-carboxylicacid, 2,3-dihydroxy-2,3-dimethylsuccinic acid, and2,4-dihydroxy-2,4-dimethylpentanedioic acid. As noted above, mixtures ofthese materials can be used in a specific complex if desired.

In other embodiments, L is represented in Structure (V) by the followingStructure (VII):

wherein R₄ is a branched or linear alkyl group having 1 to 8 carbonatoms, including branched iso- and tertiary alkyl groups having 3 to 8carbon atoms. In addition, any of the hydrogen atoms in any of thebranched or linear alkyl groups optionally can be replaced with afluorine atom; for example, the terminal carbon atom of a R₄ branched orlinear alkyl group can have 1 to 3 fluorine atoms.

Some useful conjugate acids from which the α-oxy carboxylate (L)represented by Structure (VII) can be selected from the group consistingof pyruvic acid, 3-methylpyruvic acid, 3,3-dimethylpyruvic acid,3,3-dimethyl-2-oxobutanoic acid, 3,3-dimethyl-2-oxopentanoic acid, and2,3-dioxosuccinic acid.

The “P” compound of Structure (V) is a 5- or 6-membered N-heteroaromaticcompound such as a 6-membered N-heteroaromatic compound. Such 5- or6-membered N-heteroaromatic compounds can have a pK_(a) of at least 10and up to and including 22. An experimental method for measuring pK_(a)and the pK_(a) values of some N-heteroaromatic bases are known (forexample, see Kalijurand et al. J. Org. Chem. 2005, 70, 1019).

In general, each 5- or 6-membered N-heteroaromatic compound isnon-polymeric in nature and has a molecular weight of 200 or less. By“5- or 6-membered,” it is meant that the N-heteroaromatic compound haseither 5 or 6 atoms in the heterocyclic aromatic ring, at least one ofwhich atoms is a nitrogen atom. In general, such heterocyclic aromaticrings generally have at least one carbon atom and at least one nitrogenatom in the ring.

In Structure (V) shown above, c is 1, 2, 3, or 4, and in the embodimentswhere c is 2, 3, or 4, the multiple 5- or 6-membered N-heteroaromaticcompound molecules within the single complex molecule can be the same ordifferent. For example, the 5- or 6-membered N-heteroaromatic compoundcan be selected from the group consisting of pyridine, 2-methylpyridine,4-methylpyridine, 2,6-dimethylpyridine, 2,3-dimethylpyridine,3,4-dimethylpyridine, 4-pyridylacetone, 3-chloropyridine,3-fluoropyridine, oxazole, 4-methyloxazole, isoxazole,3-methylisoxazole, pyrimidine, pyrazine, pyridazine, and thiazole.

Representative 5- or 6-membered N-heteroaromatic compounds can bereadily obtained from various commercial chemical suppliers located invarious countries.

Further details of properties, representative compounds, and methods ofmaking them are provided in copending and commonly assigned U.S. Ser.No. 15/231,804 (filed Aug. 9, 2016 by Shukla), the disclosure of whichis incorporated herein by reference. Of these types of reducible silverion-containing complexes, a silver α-oxycarboxylate pyridine complexsuch as silver lactate pyridine complex, is particularly useful.

(vi) Still other useful silver complexes are designed with one or two(b) reducible silver ions as described above for the (iv) silvercomplexes, complexed with both one or two a-oxy carboxylate molecules asdescribed above for the (iv) silver complexes, and one, two, three, orfour primary alkylamine molecules. In general, such useful silvercomplexes can be represented by the following Structure (VIII):

wherein L represents the α-oxy carboxylate; P represents the primaryalkylamine; a is 1 or 2; b is 1 or 2; and c is 1, 2, 3, or 4, providedthat when a is 1, b is 1, and when a is 2, b is 2.

In such complexes, P is a primary alkylamine having a boiling point ofless than or equal to 175° C., or having a boiling point of less than orequal to 125° C., or even at least 75° C. and up to and including 125°C., at atmospheric pressure. The useful primary alkyl amines thatgenerally have a molecular weight of less than 500 and are thusconsidered “non-polymeric” as defined by molecular weight and boilingpoint.

The term “primary alkylamine” refers herein to compounds that arenon-aromatic and are not cyclic in structure. They generally have one ormore nitrogen atoms as long as all other features (molecular weight,pKa, boiling point, and oxidation potential) described herein are met.In such compounds, each of the nitrogen atoms has two valences filled byhydrogen atoms and the remaining valence of each nitrogen atom is filledwith a substituted or unsubstituted alkyl group (not including alkylarylgroups such as benzyl groups), or with a substituted or unsubstitutedalkylene group for compounds defined herein as “primary alkyl diamines”that can be illustrated by the following Structure (IX):

wherein R₅ represents a substituted or unsubstituted, branched orlinear, divalent alkylene group having 1 to 5 carbon atoms; and optionalsubstituents include but are not limited to, fluoride atoms for any ofthe hydrogen atoms in the alkylene group.

In most useful embodiments, the primary alkyl amines comprise a singlenitrogen atom and a single substituted or unsubstituted, branched orlinear alkyl group having at least 3 carbon atoms, and generally from 3to 6 carbon atoms, wherein any of the hydrogen atoms of the alkyl groupcan be replaced with a fluorine atom.

Representative useful primary alkylamines can be selected from the groupconsisting of a propylamine, n-butylamine, t-butylamine, isopropylamine,2,2,2-trifluoroethylamine, 2,2,3,3,3-pentafluoropropylamine,3,3,3-trifluoropropylamine, 1,2-dimethylpropylamine, t-amyl amine, andisopentylamine. Other useful primary alkylamines would be readilyapparent to one skilled in the art. In some embodiments, the primaryamine has an asymmetric carbon center on an alkyl chain. Some examplesof such amines include but not limited to, a 2-amino-3-methylbutane,3,3-dimethyl-2-butylamine, 2-aminohexane, sec-butylamine, and othersthat would be readily apparent to one skilled in the art from theforegoing description. Such primary alkylamines can be substituted withother groups that would be readily apparent to one skilled in the art.

Useful primary alkyl amines can be readily obtained from variousworldwide commercial sources of chemicals.

Further details of properties, representative compounds, and methods ofmaking them are provided in copending and commonly assigned U.S. Ser.No. 15/231,837 (filed Aug. 9, 2016 by Shukla), the disclosure of whichis incorporated herein by reference.

(vii) Yet other useful reducible silver ion-containing complexes aredesigned with one or two (b) reducible silver ions as described abovefor the (iv) silver complexes, complexed with both one or two α-oxycarboxylate molecules as described above for the (iv) silver complexes,and one, two, three, or four oxime compound molecules. In general, eachuseful silver complex can be represented by the following Structure (X):

wherein L represents the α-oxy carboxylate; P represents an oximecompound; a is 1 or 2; b is 1 or 2; and c is 1, 2, 3, or 4, providedthat when a is 1, b is 1, and when a is 2, b is 2.

In the noted Structure (X), the “P” compound is an oxime compound (or amixture of two or more different oxime compounds). Traditionally, an“oxime” has a general formula of >C═N—OH. In the present invention, theterm “oxime compound” is meant to include such compounds as well ascompounds in which the hydrogen is replaced with a suitable monovalentradical. In general, the oxime compounds useful herein are not polymericin nature and each has a molecular weight of 200 or less, or of 150 orless.

In Structure (X) shown above, c is 1, 2, 3, or 4, and in the embodimentswhere c is 2, 3, or 4, the P molecules within the single complexmolecule can be the same or different oxime compounds.

For many embodiments, P can be an oxime compound that can be representedby the following Structure (XI):

wherein R₅ and R₆ are independently hydrogen or a substituted orunsubstituted alkyl group having 1 to 6 carbon atoms (linear orbranched), provided that at least one of R₅ and R₆ is one of such alkylgroups. Alternatively, R₅ and R₆ can together represent the carbon atomssufficient to provide a substituted or unsubstituted 5- or 6-membered,saturated carbocyclic ring, such as a substituted or unsubstitutedpentane ring or substituted or unsubstituted cyclohexane ring.

R₇ is hydrogen, a substituted or unsubstituted alkyl group having 1 to 6carbon atoms (linear or branched), a substituted or unsubstituted acylgroup having 1 to 6 carbon atoms (linear or branched), a —C(═O)R₈ group,or a carbonyloxyalkyl group [—C(═O)OR₈], wherein R₈ is hydrogen or asubstituted or unsubstituted alkyl having 1 to 6 carbon atoms (linear orbranched).

Representative oxime compounds useful in the practice of the presentinvention include but are not limited to, acetoxime (acetone oxime),acetaldoxime, Aldicarb, dimethylglyoxime, methylethyl ketone oxime,propionaldehyde oxime, cyclohexanone oxime, cyclopentanone oxime,heptanal oxime, acetone-O-methyl oxime, acetaldehyde-O-methyl oxime,propionaldehyde-O-methyl oxime, butanaldehyde-O-methyl oxime,2-butanone-O-methyl oxime, cyclopentanone-O-methyl oxime, and2-butanone-O-ethyl oxime.

Some representative oxime compounds can be readily obtained from variouscommercial chemical suppliers such as Sigma Aldrich. Further details ofproperties, representative examples, and methods of making them areprovided in copending and commonly assigned U.S. Ser. No. 15/362,868(filed Nov. 29, 2016 by Shukla et al.), the disclosure of which isincorporated herein by reference.

In the non-aqueous silver precursor composition, according to thepresent invention, the amounts of the (b) reducible silver ions can bevaried depending upon the particular manner in which the composition isto be used. In general, the (b) reducible silver ions are present at aweight ratio to the one or more (a) polymers of at least 5:1 and up toand including 50:1, or even at least 5:1 and up to and including 20:1,as described above.

(c) Organic Solvents Used in Making of Silver Nanoparticles

The organic solvent(s) used in the practice of this invention are notparticularly limited as long as the nitrogenous base and compoundscontaining (b) reducible silver ions can be readily dissolved ordispersed therein. It is useful that each (c) organic solvent used inthe non-aqueous silver precursor composition or the non-aqueoussilver-containing dispersion (described below) has a boiling pointgreater than or equal to 90° C., or at least 100° C., at least 150° C.and at least >200° C. but generally less than 500° C. If two or moredifferent organic solvents are used, the difference of the boilingpoints of any two organic solvents can be greater than >10° C.

In the practice of the present invention, the (c) organic solventsuseful in the practice of this invention can be selected to have a totalHansen parameter that is compatible with the total Hansen parameter ofthe one or more (a) polymers (such as one or more cellulosic polymers)that are to be incorporated into the silver nanoparticle composite. Itis desirable that the total Hansen parameters of the one or more (a)polymers and the one or more (c) organic solvents lie within a certainrange, and it is especially desirable to maintain the desired totalHansen parameter as the organic solvent profile changes during thedeposition processes. Typically, the (c) organic solvents have a totalHansen parameter equal to or greater than the total Hansen parameter ofthe one or more (a) polymers (such as one or more cellulosic polymers).Thus, if a mixture of (c) organic solvents is used, it is desirable thatthe total Hansen parameter of the organic solvent mixture is equal to orgreater than the total Hansen parameter of the one or more (a) polymers(such as one or more cellulosic polymers) to be incorporated within thesilver nanoparticle composite. Some useful dispersions comprise organicsolvent blends that maintain desirable total Hansen parameters even asthe (c) organic solvents are removed during and after the depositionprocesses (described below).

Thus, in all embodiments of the non-aqueous silver precursorcomposition, the (a), (b), and (d) components are dispersed or dissolvedin an (c) organic solvent medium that consists of one or more organicsolvents described herein, and especially one or more hydroxylic organicsolvents, each of which has an α-hydrogen atom and properties definedbelow. It is particularly useful that the (a) polymer(s) are soluble inthe one or more (c) organic solvents.

Useful hydroxylic solvents can be alcohols having an α-hydrogen atom.Accordingly, primary and secondary alcohols are useful and they can bemonohydric or polyhydric. While either saturated or unsaturated alcoholscan be used, it is desirable that the alcohol used be free from olefinicunsaturation. Suitable alcohols can be of either straight-chain orbranched-chain configuration, and can contain in their structure eitheror both of alicyclic or aromatic carbon-to-carbon moieties.Representative examples of suitable straight-chain primary alcoholsinclude but are not limited to, ethanol, n-propanol, n-butanol,n-pentanol, n-hexano, 1,1-octanol, 2-ethyl-1-hexanol, n-decanol,ethylene glycol, propylene glycol, and benzyl alcohol. Representativeexamples of branched-chain alcohols include isobutyl alcohol, isoamylalcohol, and secondary butyl carbinol. Secondary alcohols have greaterreactivity. Representative examples of secondary alcohols include butare not limited to, isopropyl alcohol, secondary butyl alcohol,secondary amyl alcohol, diethyl carbinol, methyl isobutyl carbinol,methyl-3-heptanol, diisobutyl carbinol, dodecanol-Z, methyl allylcarbinol, cyclohexanol, methyl cyclohexyl carbinol, phenyl methylcarbinol, and similar materials. Combinations of any of these alcoholscan be used if desired. Such materials can be readily purchased fromvarious commercial sources or readily prepared using known startingmaterials, conditions, and reaction schemes.

Glycol ethers with both an ether and alcohol functional group in thesame molecule are particularly useful in the practice of the presentinvention. Representative examples of such glycol ethers include but arenot limited to, 2-methoxyethanol, 2-ethoxyethanol, diethylene glycolmonoethyl ether (carbitol), and methoxy isopropanol. Mixtures of thesecompounds can be used if desired. Such glycol ethers are commerciallyavailable.

Minor amounts of water can be present, but the total weight % of waterin the non-aqueous silver precursor composition is generally less than10%.

(d) Nitrogenous Bases:

Another essential component of the non-aqueous silver precursorcompositions according to the present invention is a nitrogenous basehaving a pKa in acetonitrile of at least 15 and up to and including 25at 25° C. Such one or more nitrogenous bases are generally present in anequimolar amount or molar excess relative to the amount of (b) reduciblesilver ions, described above.

In general, the nitrogenous bases can be cyclic or acyclic alkyl amines.All primary amines, secondary amines, or tertiary amines are useful inthe present invention. Some especially useful amines are1,4-diazabicyclo[2.2.2]octane (DABCO), cyclohexylamine, pipperidine,N-methyl pipperidine, N-methyl-3-piperidinol, and others that would bereadily apparent to one skilled in the art. Combinations of two or moreof these compounds can be used if desired.

The nitrogenous base can be an alkanolamines including but are notlimited to, ethanol amine, 2-(ethylamino)ethanol,2-(methylamino)ethanol, 2-(butylamino)ethanol, methyldiethanolamine(MDEA), diethanolamine (DEA), diglycolamine (DGA), diethylaminoethanol(DEAE), and others that would be readily apparent to one skilled in theart. Combinations of two or more of these compounds can be used ifdesired.

Nitrogen-containing heterocyclic compounds are also useful asnitrogenous bases in the present invention. Such compounds can be arearomatic and heterocyclic in nature and comprise at least one nitrogenatom in the aromatic heterocyclic ring. Such compounds can also besubstituted or unsubstituted as desired. Representative aromaticheterocyclic, nitrogen-containing bases useful in this invention includebut are not limited to, substituted or unsubstituted, non-polymericpyridine, picolines, lutidines, quinoline, purine, isoquinoline,imidazole, benzimidazole, benzthiazole, thiazole, oxazole, benzoxazole,4,4′-bipyridine, pyrazine, triazine, pyrimidine, nicotinic acid, andisonicotinic acid compounds. Mixtures of two or more these or otherunnamed compounds can be used if desired, in any useful proportion. Thesubstituted or unsubstituted pyridines are particularly useful.

Other useful nitrogenous bases include amidines such as1,8-diazabicyclo[5.4.0]undec-7-ene (DBU).

It is essential that the nitrogenous base has a pKa of at least 15 andup to and including 20, or more typically of at least 18 and up to andincluding 25, as measured in acetonitrile. An experimental method formeasuring pKa, and the pKa values of some aromatic heterocyclic andamine nitrogenous bases are known (for example, see Kalijurand et al. J.Org. Chem. 2005, 70, 1019; and Cantu et al. Journal of Chromatography A,2005, 1068, 99).

In general, each nitrogenous base used in the present invention is inliquid form and has a boiling point equal to or higher than each of theone or more (c) organic solvents, for example, each of the one or morehydroxylic solvents. Thus, the boiling point of the nitrogenous base atatmospheric pressure is at least 100° C. and up to but less than 500°C., or at least 120° C. and up to and including 350° C., or up to andincluding 250° C.

Useful nitrogenous bases can be readily obtained from commercialsources.

Non-Aqueous Silver-Containing Dispersions

The reducible silver ions in a non-aqueous silver precursor compositionaccording to the present invention can be converted into silvernanoparticles in silver nanoparticle composites to provide acorresponding non-aqueous silver-containing dispersion using theoperations described below for the methods according to this invention.

Such non-aqueous silver-containing dispersions comprise one or moresilver nanoparticle composites, each comprising silver and one or moreof the (a) polymers described above. The amount of such silvernanoparticle composites in the non-aqueous silver-containing dispersionwould generally be the total weight of silver and (a) polymers in thenon-aqueous silver-containing dispersion but it could be less, dependingupon how much of the (b) reducible silver ions are reduced and how muchfree silver, (b) reducible silver ions, and free (a) polymers arepresent in the non-aqueous silver-containing dispersion after silver ionreduction, silver nanoparticle composite isolation, and re-dispersion(described below).

As noted above, it is desired that a high amount of the reducible silverions be converted to silver metal and thus, the non-aqueoussilver-containing dispersion would contain silver in an amount of up toand including 100 mol % of the original (b) reducible silver ions in thenon-aqueous silver precursor composition.

The non-aqueous silver-containing dispersion contains one or more (c)organic solvents (such as hydroxylic organic solvents) as describedabove. Such organic solvents can be same or different as those used tomake the non-aqueous silver precursor compositions. These (c) organicsolvents can be those originally in the non-aqueous silver precursorcomposition (that is, before isolation and re-dispersion of the silvernanoparticle composite), or they can be added during re-dispersion ofthe silver nanoparticle composite.

(d) Nitrogenous base is also generally present in the non-aqueoussilver-containing dispersion although much of the original amount thatwas present in the non-aqueous silver precursor composition may bewashed out during isolation of the silver nanoparticle composite.However, it is evident that some (d) nitrogenous base remains with thesilver nanoparticle composite upon its re-dispersion in one or more (c)organic solvents. The amount of such nitrogenous base(s) in thenon-aqueous silver-containing dispersion is generally up to andincluding 10 weight %, based on the total weight of silver metal (notincluding any remaining reducible silver ions).

(e) Carbon Black:

In some embodiments, (e) carbon black can be incorporated into thenon-aqueous silver-containing dispersions at a suitable time. Carbonblack can be obtained commercially in various forms. The (e) carbonblack can be added so that it is present in an amount of at least 5weight %, based on (or relative to) the total weight of the one or more(a) polymers. Typically, the amount of (e) carbon black is at least 5weight % and up to and including 50 weight %, or more typically in anamount of at least 5 weight % and up to and including 25 weight %, basedon (or relative to) the total weight of the one or more (a) polymers.

Articles

The non-aqueous silver-containing dispersions prepared according to thepresent invention can be used to provide articles that can then be usedin various operations or devices.

An article (or element) is typically designed to have a substrate havingthereon a dry layer or dry pattern comprising a silver nanoparticlecomposite composition. The article has silver nanoparticles and noappreciable amounts of (b) reducible silver ions. That is, the (b)reducible ions are generally present in an amount of less than 5 mol %,based on the total amount of silver in the dry layer or dry pattern.

Thus, each article comprises a substrate (described below), and can havedisposed on at least one supporting surface (or side) thereof a drylayer or dry pattern of a dry silver nanoparticle composite compositioncomprising:

a silver nanoparticle composite comprised of silver and one or more (a)polymers selected from one or more of cellulose acetate, celluloseacetate phthalate, cellulose acetate butyrate, cellulose acetatepropionate, cellulose acetate trimellitate, hydroxypropylmethylcellulose phthalate, methyl cellulose, ethyl cellulose, hydroxyethylcellulose, hydroxypropylmethyl cellulose, carboxymethyl cellulose, andcombinations thereof; and one or more nitrogenous bases as describedabove.

These silver nanoparticle composites generally have a mean particle size(d50) of at least 10 nm and up to and including 1500 nm, or of at least20 nm and up to and including 500 nm, or even of at least 50 nm and upto and including 350 nm.

Carbon black can also be present in the dry silver nanoparticlecomposite composition in an amount of up to and including 50 weight %,or at least 5 weight % and up to and including 50 weight %, or even atleast 5 weight % and up to and including 25 weight %, all based on (orrelative to) the total weight of the one or more (a) polymers.

Such dry layers or dry patterns generally contain less than 5 mol %, orless than 2 mol %, or even less than 1 mol %, of (b) reducible silverions, all based on the total molar amount of silver in the dry patternor dry layer.

When one or more dry patterns of a silver nanoparticle compositecomposition are formed on the substrate, at least one of the patternscan comprise a combination of fine lines, each fine line having anaverage dry width of at least 1 μm and up to and including 20 μm, whichcombination of fine lines can be arranged in parallel, crossing at anydesired angle, a combination thereof, or in a random arrangement. Eachdry pattern can be designed to have any predetermined grid pattern thatcan be achieved in the art.

The presence of the (e) carbon black in the dry patterns is particularlyadvantageous when the substrate (described in detail below) istransparent, such as a transparent continuous polymeric film (forexample a transparent continuous polycarbonate, polystyrene, orpolyester film).

In many embodiments of articles, the substrate has a first supportingsurface (or side) and a second opposing supporting surface (or side),and one or more dry patterns of the silver nanoparticle compositecomposition are disposed on the first supporting surface, andoptionally, one or more dry patterns of the same or different silvernanoparticle composite composition are disposed on the second opposingsupporting surface. The dry patterns can be disposed on the two opposingsupporting surfaces of the substrate in any opposing arrangement, thatis either directly opposite one another, or offset in some desiredarrangement.

For example, in some embodiments of the article, the substrate is atransparent continuous polymeric (such as polyester) film (or web) thathas a first supporting surface and a second opposing supporting surface,

the article further comprising multiple (two or more) individual drypatterns formed on the first supporting surface comprise the same ordifferent silver nanoparticle composite composition, and furthercomprising multiple (two or more) individual dry patterns formed on thesecond opposing supporting surface which opposing multiple dry patternscomprise the same or different silver nanoparticle compositecomposition.

For example, in such embodiments, all of the multiple individual drypatterns on both the first supporting surface and the second opposingsupporting surface can comprise the same silver nanoparticle compositecomposition, the silver nanoparticle composite composition in eachindividual dry pattern comprises silver nanoparticle composite(s) havinga mean particle size (d50) of at least 50 nm and up to and including 300nm, and each of the multiple individual dry patterns comprises finelines having an average dry width of at least 1 μm and up to andincluding 20 μm.

The articles described herein comprise a suitable substrate thatgenerally has two planar surfaces: a first supporting side (or surface)and a second opposing supporting side (or surface). Such substrates canhave any suitable form such as sheets of any desirable size and shape,webs of metals, films, and elongated fibers or woven fibers (such as inwebs of textiles) or other porous materials, and especially continuouswebs of various transparent, translucent, or opaque polymeric materials(such as polycarbonates and polyesters) that can be supplied, used, orstored as rolls. Such continuous webs or films can be used in continuousroll-to-roll manufacturing operations where the continuous web isunrolled from a supply roll and taken up using a take-up roll.

More specifically, a uniform thin film or one or more thin film patternsof a silver nanoparticle composite composition are provided in asuitable manner on one or more supporting sides of a suitable substrateto provide an article as described according to the methods describedbelow. Typically, such articles have an initially “wet” non-aqueoussilver-containing dispersion layer or pattern during and immediatelyafter application to the substrate but the hydroxylic organic solventscan be removed as described below to provide the desired uniform thinfilm layer or one or more thin film patterns.

Suitable substrates can be composed of any suitable material that doesnot inhibit the purpose of the present invention and eventual uses ofthe articles. For example, substrates can be formed from materialsincluding but are not limited to, polymeric films, metals, glasses(untreated or treated for example with tetrafluorocarbon plasma,hydrophobic fluorine, or a siloxane water-repellant material), siliconor ceramic materials such as ceramic wafers, fabrics, papers, andcombinations thereof (such as laminates of various films, or laminatesof papers and films) provided that a uniform thin film or thin filmpattern can be formed thereon in a suitable manner and followed bythermal treatment (heating) on at least one supporting surface thereof.The substrate can be transparent, translucent, or opaque, and rigid orflexible. The substrate can include one or more auxiliary polymeric ornon-polymeric layers or one or more patterns of other materials beforethe non-aqueous dispersion is applied according to the presentinvention.

More specifically, suitable substrate materials for forming precursorand product articles according to the present invention include but arenot limited to, metallic films or foils, metallic films on polymer,glass, or ceramic materials, metallic films on electrically conductivefilm supports, semi-conducting organic or inorganic films, organic orinorganic dielectric films, or laminates of two or more layers of suchmaterials. Useful substrates can include transparent polymeric filmssuch as poly(ethylene terephthalate) films, poly(ethylene naphthalate)films, polyimide films, polycarbonate films, polyacrylate films,polystyrene films, polyolefin films, and polyamide films, silicon andother ceramic materials, metal foils such as aluminum foils, cellulosicpapers or resin-coated or glass-coated papers, glass or glass-containingcomposites, metals such as aluminum, tin, and copper, and metalizedfilms. Porous fabrics, glasses, and polymeric webs can also be used.

Particularly useful substrates including continuous flexible polymericfilms, metal foils, and textile webs. Useful continuous flexiblepolymers films include transparent continuous polymeric films such astransparent continuous polyester films such as films of poly(ethyleneterephthalate), polycarbonate films, or poly(vinylidene chloride) filmswith or without surface-treatments or coatings as noted below.

For example, either or both supporting surfaces of the substrate can betreated with a primer layer or receptive layer, or with electrical ormechanical treatments (such as graining) to improve adhesion of thesilver nanoparticle composite composition. An adhesive layer can bethermally activated, solvent activated, or chemically activated. Aseparate receptive layer can have any suitable dry thickness of at least0.05 μm when measured at 25° C.

The two supporting surfaces of the substrate, especially polymericsubstrates, can be treated by exposure to corona discharge, mechanicalabrasion, flame treatments, or oxygen plasmas, or coated with variouspolymeric films, such as poly(vinylidene chloride) or an aromaticpolysiloxane.

Useful substrates can have a desired dry thickness depending upon theeventual use of the articles. For example, the substrate dry thickness(including all treatments and auxiliary layers) can be at least 0.001 mmand up to and including 10 mm, and especially for transparent polymericfilms, the substrate dry thickness can be at least 0.008 mm and up toand including 0.2 mm.

The substrate used in the articles described herein can be provided invarious forms, such as for example, individual sheets of any size orshape, and continuous webs such as continuous webs of transparentsubstrates (including transparent continuous polyester films). Suchcontinuous webs can be divided or formed into individual first, second,and additional portions on a first supporting surface and a secondopposing supporting surface on which can formed the same or differentcorresponding silver nanoparticle composite composition patterns in thedifferent (or individual) portions of a supporting side (such as thefirst supporting sides).

Methods for Forming Silver-Containing Dispersions

Non-aqueous silver-containing dispersions according to the presentinvention comprising the silver nanoparticle composite described abovecan be provided using either of two methods (Methods I and II) accordingto the present invention. In both methods, the one or more (a) polymers(as described above) are mixed (or dissolved) in one or more (c) organicsolvents (described above) using suitable stirring and mixingconditions.

Method I:

In a first method, one or more (d) nitrogenous base(s) (as describedabove) are mixed within the one or more (c) organic solvents (asdescribed above) along with the one or more (a) polymers (as describedabove), to form a premix solution. This premix solution can be heated toa temperature of at least 75° C. and more likely to a temperature of atleast 75° C. and up to and including 125° C. using any suitable heatingmeans. During this heating operation, the premix solution can becontinuously stirred using suitable stirring mechanism or apparatus.

While keeping this premix solution stirred at the noted temperature ofat least 75° C., a solution of (b) reducible silver ions (in any silverion-containing form as described above) in one or more (c) organicsolvents (same or different from those already in premix solution) canbe added to the premix solution. The rate of addition of (b) reduciblesilver ions can be varied, for example, by using a peristaltic pump.This addition process is generally at a rate sufficient at the notedtemperature to promote the extensive reduction of the (b) reduciblesilver ions, for example at least 90 mol % reduction based on theoriginal amount of (b) reducible silver ions. In general, the finalamount of added (b) reducible silver ions in the premix solution isequimolar or less in relation to the (d) nitrogenous base(s) present inthe premix solution. In addition, the final weight ratio of the (b)reducible silver ions to the one or more (a) polymers is at least 5:1and up to and including 50:1, or at least 60:1 and up to and including75:1.

The result of this addition operation is the relatively rapid formationof one or more silver nanoparticle composites in a reaction mixture.

Method II:

In a second method, (b) reducible silver ions (in any silver ioncontaining-form as described above) are mixed within the one or more (c)organic solvents (as described above) along with the one or more (a)polymers (as described above), to form a premix solution. This premixsolution can be heated to a temperature of at least 75° C. and morelikely to a temperature of at least 75° C. and up to and including 125°C. using any suitable heating means. Stirring can also be carried outduring this heating operation using any suitable stirring mechanism orapparatus and in the following addition of the (d) nitrogeneous base(s).

While keeping this premix at the noted temperature of at least 75° C., asolution of one or more (d) nitrogenous bases (as described above),perhaps in one or more (c) organic solvents (same or different fromthose already in premix solution), are added to the premix solution.This addition process is generally at a rate sufficient at the notedtemperature to promote the extensive reduction of the (b) reduciblesilver ions, for example at least 80 mol % reduction based on theoriginal amount of (b) reducible silver ions. In general, the finalamount of added (d) nitrogenous base(s) in the premix solution isequimolar or in molar excess in relation to the (b) reducible silverions present in the premix solution.

The result of this addition operation is the relatively rapid formationof one or more silver nanoparticle composites in a reaction mixture.

If (e) carbon black is to be included in the non-aqueoussilver-containing dispersion, it can be incorporated and dispersedwithin at any suitable point during either Method I or Method II inappropriate amounts described above using a suitable mixing means suchas a shear mixer. Suitable shear mixers are commercially available fromvarious sources such as Silverson, Admix, and Ross.

In both Methods I and II, the resulting silver nanoparticle composite inthe reaction mixture can be cooled generally to room temperature. Thecooled silver nanoparticle composite is then isolated from the reactionmixture by either of the following two methods:

1) gravity precipitation followed by filtration of the precipitate; or

2) pouring the cooled reaction mixture into water and then filtering offthe precipitate.

The isolated silver nanoparticle composite can be dried, if desired, andstored for later use. Alternatively, the silver nanoparticle compositecan be immediately re-dispersed in one or more suitable (c) organicsolvents (same as or different from those used above) to provide anon-aqueous silver-containing dispersion containing up to 80 weight % ofsilver nanoparticle composite.

Particularly useful (c) organic solvents used for this dispersingoperation have a total Hansen parameter that is compatible with thetotal Hansen parameter of the one or more (a) polymers (such as one ormore cellulosic polymers) that have been incorporated into the silvernanoparticle composite. Typically, these (c) organic solvents have atotal Hansen parameter equal to or greater than the total Hansenparameter of the one or more (a) polymers (such as one or morecellulosic polymers). Thus, if a mixture of (c) organic solvents is usedfor dispersion, it is desirable that the total Hansen parameter of theorganic solvent mixture is equal to or greater than the total Hansenparameter of the one or more (a) polymers (such as one or morecellulosic polymers) that have been incorporated within the silvernanoparticle composite.

The non-aqueous silver-containing dispersion resulting from the methoddescribed herein can be stored for later use or immediately employed invarious additional operations, for example, to provide an article asdescribed above.

For example, a non-aqueous silver-containing dispersion can be disposedonto a substrate (as described above) using any suitable equipment andmethod as described below, and the one or more (c) organic solvents canbe removed in a suitable manner. Thus, the non-aqueous silver-containingdispersion disposed onto one or more supporting sides of a substrate toprovide, upon drying, either a dry uniform film (usually thin), or oneor more dry patterns of silver nanoparticle composite composition.Disposition of the non-aqueous silver-containing dispersion can beachieved in a variety of means known in the art for applying solutionsor dispersions to a solid substrate.

For example, in some embodiments, a variety of films, includingpolymeric films composed of polyethylene, polypropylene,biaxially-oriented polypropylene, polyethylene terephthalate,polybutylene terephthalate and polyamide, can be utilized as suitabletransparent substrates. The choice of substrate structure is not,however, limited to films but includes any material that can be formedinto bags, shrink wrap, plates, cartons, boxes, bottles, crates, andother containers. The disposition on or application to a substrate canbe carried out for example, using uniform inkjet printing, gravureprinting, screen printing, flexographic printing, or by using a bladecoating, gap coating, slot die coating, X-slide hopper coating, or knifeon roll operations.

For example, a non-aqueous silver-containing dispersion can be disposedon the substrate (one or both supporting surfaces) in a patternwisemanner using techniques described below such as flexographic printing,screen printing, gravure printing, or inkjet printing to provide one ormultiple (two or more) silver nanoparticle composite compositionpatterns on the substrate.

For example, where the substrate has a first supporting side and asecond opposing supporting side, the method according to this inventioncan also comprise disposing the non-aqueous silver-containing dispersioncontaining the silver nanoparticle composite onto the substrate in apatternwise manner to form at least one pattern (or multiple patterns)of the non-aqueous silver-containing dispersion on at least the firstsupporting side.

It is also possible for the method according to the present invention tobe used to further dispose the same or different non-aqueoussilver-containing dispersion onto the substrate in a patternwise mannerto form multiple patterns of the non-aqueous silver-containingdispersion on the second opposing supporting side, or in a manner toform multiple patterns of a non-aqueous silver-containing dispersion onboth the first supporting side and the second opposing supporting sideusing one or more flexographic printing members.

The present invention lends itself to rapid conversion of (b) reduciblesilver ions to electrically-conductive silver metal in an economical wayso the process can be incorporated into the manufacture of variousdevices containing electrically-conductive silver patterns. Suchoperations can often be achieved using a substrate that is a continuousweb that is unrolled from a supply roll and is taken up using a take-uproll, and the method is carried out in a continuous roll-to-roll manner.

More details about useful electrically-conductive silver patterns thatare achievable with the present invention are now provided.

Any applied pattern of silver nanoparticle composite composition cancomprise a grid of electrically-conductive fine lines (or other shapesincluding circles or an irregular network) as described above and theoptimal dry thickness (or width) can be tailored for an intended use.

In some embodiments, the same or different silver nanoparticle compositepattern (after drying) can be provided in a suitable manner in differentportions on both the first supporting side and the second opposingsupporting side of the substrate to form a “duplex” or dual-sidedarticle, and such patterns can be provided using the same or differentnon-aqueous silver-containing dispersion.

In many embodiments, a non-aqueous silver-containing dispersion can beapplied on one or both supporting surfaces of the substrate (for exampleas a roll-to-roll web) using flexographic printing with one or moreelastomeric relief elements such as those derived from flexographicprinting plate precursors, many of which are known in the art. Some suchprecursors are commercially available, for example as the CYREL®Flexographic Photopolymer Plates from DuPont and the Flexcel SR and NXFlexographic plates from Eastman Kodak Company.

Useful elastomeric relief elements are derived from flexographicprinting plate precursors and flexographic printing sleeve precursors,each of which can be appropriately imaged (and processed if needed) toprovide the elastomeric relief elements for “printing” suitableelectrically-conductive silver nanoparticle composite patterns. Usefulprecursors of this type are described for example, in U.S. Pat. Nos.7,799,504 (Zwadlo et al.) and 8,142,987 (Ali et al.) and U.S. PatentApplication Publication 2012/0237871 (Zwadlo), the disclosures of all ofwhich are incorporated herein by reference. Such flexographic printingprecursors can comprise elastomeric photopolymerizable layers that canbe imaged through a suitable mask image to provide an elastomeric reliefelement (flexographic printing plate or flexographic printing sleeve).The resulting relief layer can be same or different depending uponwhether the same or different patterns are to be formed on one or bothsupporting sides of the substrate.

In other embodiments, an elastomeric relief element can be provided froma direct (or ablation) laser-engraveable elastomeric relief elementprecursor, with or without integral masks, as described for example inU.S. Pat. Nos. 5,719,009 (Fan), 5,798,202 (Cushner et al.), 5,804,353(Cushner et al.), 6,090,529 (Gelbart), 6,159,659 (Gelbart), 6,511,784(Hiller et al.), 7,811,744 (Figov), 7,947,426 (Figov et al.), 8,114,572(Landry-Coltrain et al.), 8,153,347 (Veres et al.), 8,187,793 (Regan etal.), and U.S. Patent Application Publications 2002/0136969 (Hiller etal.), 2003/0129530 (Leinenback et al.), 2003/0136285 (Telser et al.),2003/0180636 (Kanga et al.), and 2012/0240802 (Landry-Coltrain et al.),the disclosures of all of which are incorporated herein by reference.

When the noted elastomeric relief elements are used to provide patterns,the non-aqueous silver-containing dispersion can be applied in asuitable manner to the uppermost relief surface (raised surface) in theelastomeric relief element. Then, application to a substrate can beaccomplished in a suitable procedure while as little as possible iscoated from the sides (slopes) or recesses of the relief depressions.Anilox roller systems or other roller application systems, especiallylow volume Anilox rollers, below 2.5 billion cubic micrometers persquare inch (6.35 billion cubic micrometers per square centimeter) andassociated skive knives can be used. In such embodiments, thenon-aqueous silver-containing dispersion can be designed to have optimalviscosity for flexographic printing. When a substrate is moved throughthe roll-to-roll handling system from a flexographic printing platecylinder to an impression cylinder, the impression cylinder appliespressure to the flexographic printing plate cylinder that transfers animage from an elastomeric relief element to the substrate.

A substrate can be “printed” one or more times using inkjet printing,gravure printing, screen printing, or flexographic printing along a web(for example, a roll-to-roll continuous web) that can contain multiplepatterns (or individual precursor articles after cutting) in multipleportions of the continuous web that is passed through various stations.The same or different non-aqueous silver-containing dispersions can beapplied (for example, printed) on one or both supporting sides of thesubstrate in the continuous roll-to-roll production operation.

After deposition of the non-aqueous silver-containing dispersion onto asubstrate, for example, in a patternwise manner using flexographicprinting, at least 75 weight % and up to and including 100 weight % ofthe (c) organi solvent(s) (described above) can be removed in anysuitable manner to form an article. For example, ambient drying can becarried out in an open environment, or the article can be subject to“active” drying operations and apparatus (for example, heated dryingchamber). Useful drying conditions can be as low as room temperature foras little as 5 seconds and up to and including several hours dependingupon the manufacturing process. In many processes, such as roll-to-rollmanufacturing operations, drying conditions can be employed at anysuitable temperature, for example greater than 50° C. to remove at least75 weight % and up to 100 weight % of all remaining organic solventswithin at least 1 second and up to and including 10 seconds or evenwithin 5 seconds.

The present invention provides at least the following embodiments andcombinations thereof, but other combinations of features are consideredto be within the present invention as a skilled artisan would appreciatefrom the teaching of this disclosure:

1. A method comprising, in sequence:

-   A) mixing:

(a) one or more polymers selected from one or more of cellulose acetate,cellulose acetate phthalate, cellulose acetate butyrate, celluloseacetate propionate, cellulose acetate trimellitate, hydroxypropylmethylcellulose phthalate, methyl cellulose, ethyl cellulose, hydroxyethylcellulose, hydroxypropylmethyl cellulose, and carboxymethyl cellulose;

(b) reducible silver ions present in an amount of a weight ratio of (b)reducible silver ions to the one or more (a) polymers of at least 5:1and up to and including 50:1; and

(c) one or more organic solvents, each of which has a boiling point atatmospheric pressure of at least 100° C. and up to but less than 500°C., wherein the Hansen parameter (δ_(T) ^(Polymer)) of each of the oneor more polymers is less than or equal to the Hansen parameter (δ_(T)^(Solvent)) of each of the one or more organic solvents,

to form a premix solution;

-   B) heating the premix solution to a temperature of at least 75° C.;-   C) while keeping the premix solution at the temperature of at least    75° C., adding a (d) nitrogenous base having a pKa in acetonitrile    of at least 15 and up to and including 25 at 25° C., to provide a    concentration of the (d) nitrogenous base in an equimolar amount or    in molar excess in relation to the amount of (b) reducible silver    ions,

to form a silver nanoparticle composite;

-   D) after cooling, isolating the silver nanoparticle composite; and-   E) re-dispersing the silver nanoparticle composite in the same or    different one or more (c) organic solvents used in A), to provide a    non-aqueous silver-containing dispersion comprising the silver    nanoparticle composite.

2. The method of embodiment 1, further comprising:

-   disposing the non-aqueous silver-containing dispersion onto a    substrate, and-   removing the same or different one or more (c) organic solvents.

3. The method of embodiment 2, comprising disposing the non-aqueoussilver-containing dispersion onto the substrate in a patternwise manner.

4. The method of embodiment 2 or 3, comprising disposing the non-aqueoussilver-containing dispersion onto the substrate using inkjet printing,screen printing, flexographic printing, or gravure printing.

5. The method of any of embodiments 2 to 4, wherein the substrate has afirst supporting side and a second opposing supporting side, and themethod comprises disposing the non-aqueous silver-containing dispersiononto the substrate in a patternwise manner to form at least one patternof the non-aqueous silver-containing dispersion on at least the firstsupporting side.

6. The method of embodiment 5, wherein the substrate is a continuouspolymeric film, and the method comprises disposing the non-aqueoussilver-containing dispersion onto the substrate in a manner to formmultiple patterns of the non-aqueous silver-containing dispersion on atleast the first supporting side.

7. The method of embodiment 6, further comprising disposing thenon-aqueous silver-containing dispersion onto the substrate in a mannerto form multiple patterns of the non-aqueous silver-containingdispersion on the second opposing supporting side.

8. The method of embodiment 6, comprising disposing the non-aqueoussilver-containing dispersion onto the substrate to form multiplepatterns of the non-aqueous silver-containing composition on both thefirst supporting side and the second opposing supporting side using oneor more flexographic printing members.

9. The method of any of embodiments 1 to 8, wherein the substrate is acontinuous web that is unrolled from a supply roll and is taken up usinga take-up roll, and the method is carried out in a continuousroll-to-roll manner.

10. The method of any of embodiments 1 to 9, wherein the silver ispresent in the non-aqueous silver-containing dispersion at a weightratio to the one or more (a) polymers of at least 5:1 and up to andincluding 20:1.

11. The method of any of embodiments 1 to 10, wherein the one or more(c) organic solvents is one or more hydroxylic organic solvents eachhaving an α-hydrogen atom and is chosen from the group consisting ofethanol, n-propanol, n-butanol, n-pentanol, n-hexanol, n-octanol,2-ethyl-1-hexanol, n-decanol, ethylene glycol, propylene glycol, benzylalcohol, isobutyl alcohol, isoamyl alcohol, secondary butylcarbinol,isopropyl alcohol, secondary butyl alcohol, secondary amyl alcohol,diethyl carbinol, methyl isobutyl carbinol, methyl-3-heptanol,diisobutyl carbinol, dodecanol-Z, methyl allyl carbinol, cyclohexanol,methyl cyclohexyl carbinol, phenyl methyl carbinol, 2-methoxyethanol,2-ethoxyethanol, diethylene glycol monoethyl ether, methoxy isopropanol,and a combination thereof.

12. The method of any of embodiments 1 to 11, wherein the nitrogenousbase is an aromatic cyclic compound.

13. The method of any of embodiments 1 to 12, wherein the nitrogenousbase is selected from the group consisting of1,4-diazabicyclo[2.2.2]octane (DABCO), cyclohexylamine, piperidine,N-methyl pipperidine, N-methyl-3-piperidinol, ethanol amine,2-(ethylamino)ethanol, 2-(methylamino)ethanol, 2-(butylamino)ethanol,methyldiethanolamine (MDEA), diethanolamine (DEA), diglycolamine (DGA),diethylaminoethanol (DEAE), substituted or unsubstituted non-polymericpyridine, picolines, lutidines, quinoline, purine, isoquinoline,imidazole, benzimidazole, benzthiazole, thiazole, oxazole, benzoxazole,4,4′-bipyridine, pyrazine, triazine, pyrimidine, nicotinic acid,isonicotinic acid compounds, 1,8-diazabicyclo[5.4.0]undec-7-ene (DBU),and a combination thereof.

14. The method of any of embodiments 1 to 13, wherein the (a) one ormore polymer is one or more of carboxymethyl cellulose, celluloseacetate butyrate, ethyl cellulose, cellulose acetate, and celluloseacetate propionate.

15. The method of any of embodiments 1 to 14, wherein the non-aqueoussilver-containing dispersion further contains (e) a carbon black. 16.The method of any of embodiments 1 to 15, wherein the non-aqueoussilver-containing dispersion has a viscosity of at least 1 centipoise(0.001 Pascal sec) and up to and including 5000 centipoise (5 Pascalsec) at 25° C.

17. The method of any of embodiments 1 to 16, whrein the non-aqueoussilver-containing dispersion has a viscosity of at least 3 centipoise(0.003 Pascal sec) and up to and including 10 centipoise (0.01 Pascalsec) at 25° C.

The following Examples are provided to illustrate the practice of thisinvention and are not meant to be limiting in any manner.

Invention Example 1: Preparation of Non-Aqueous Dispersion ContainingSilver Nanoparticle-Cellulose Acetate Composite Using 2-ButylAminoethanol as the Nitrogenous Base

In a 2-necked round bottomed flask a mixture of cellulose acetate (0.375g; Aldrich, mol.wt. of 50,000, acetyl content of 39%) and 2-butylaminoethanol (0.9 g) in 2-methoxyethanol (8 ml) was heated at 95° C.with stirring until all cellulose acetate was dissolved to form a premixsolution. A solution of silver nitrate (5 g) dissolved in2-methoxyethanol (15 ml) was slowly added to form a reaction mixtureover a period of 20 minutes. During this addition, the reaction mixturebecame dark grey in color. It was stirred at 95° C. for another 30minutes, cooled, and poured into methanol (500 ml). The resultingprecipitate (silver nanoparticle-cellulose acetate composite) wasfiltered and washed with methanol to yield a gray solid (yield 98% basedon theoretical silver).

Particle size distribution was measured using a dynamic light scatteringmethod (Malvern Instruments Ltd. Zetasizer Nano-ZS (ZEN) Dynamic LightScattering or QELS: Quasi-Elastic Light Scatter). The median silvernanoparticle composite particle diameter [Dv (50%)] was 90 nm. (see FIG.1). The silver content of the silver nanoparticle-cellulose acetatecomposite was measured using thermogravimetric analysis (TGA) using asmall amount of obtained gray solid that was scanned at temperaturesranging from room temperature to 700° C. in air. Organic materials areburnt and removed during the TGA scan. The residual weight at 700° C.corresponded to the amount of silver in the solid. Consistent with thestarting weight ratios, the gray solid comprised 89% by weight of silverand 11% weight total of cellulose acetate and nitrogenous base.

The cooled gray-colored silver nanoparticle composite (4 g) thusobtained was added to 1-methylamino ethanol (10 ml) and re-dispersed byusing a a high shear mixer (Silverson L4R) to provide a non-aqueoussilver-containing dispersion containing containing the silvernanoparticle composite at 40 weight %.

A pattern of fine lines of nominal width of 7-10 μm was successfullyformed from this non-aqueous silver-containing dispersion on apoly(ethylene terephthalate) film substrate using a flexographic testprinter IGT F1 and flexographic printing members obtained fromcommercially available Kodak Flexcel NX photopolymer plates that hadbeen imaged using a mask that was written using the Kodak Square Spotlaser technology at a resolution of 12,800 dpi.

Invention Example 2: Preparation of Non-Aqueous Dispersion ContainingSilver Nanoparticle-Cellulose Acetate Propionate Composite Using2-Methyl Aminoethanol as the Nitrogenous Base

In a 2-necked round bottomed flask. a mixture of cellulose acetatepropionate (0.18 g; Eastman CAP 482-0.5, propionyl content 43%, Acetylcontent 0.6%, mol. wt. of 25,000) and 2-methyl aminoethanol (1.5 g,mmol) in 2-methoxyethanol (7 ml) was heated at 95° C. with stirringuntil all cellulose acetate propionate was dissolved to form a premixsolution. A solution of silver nitrate (5 g) dissolved in2-methoxyethanol (15 ml) was added to the premix solution over a periodof 35 minutes. The resulting reaction mixture was stirred at 95° C. foranother 45 minutes, cooled, and poured into water (400 ml). Theresulting precipitate was filtered and washed with methanol. A greycolored solid was obtained (yield of 97% based on silver). Particle sizedistribution was measured using a dynamic light scattering method(Malvern Instruments Ltd. Zetasizer Nano-ZS (ZEN) Dynamic LightScattering or QELS: Quasi-Elastic Light Scatter). The median particlediameter [Dv (50%)] was 340 nm determined. (see FIG. 2).

Chemical analysis of the resulting solid was carried out by TGA-FTIR(Thermo Gravimetric Analysis-Forier Transform Infrared) on a 95.1 mgsample over the temperature range of room temperature to 700° C., usinga ramp protocol of 10 degrees/minute to 150° C. (isotherm 15 minutes),10 degrees/minute to 250° C. (isotherm 15 minutes), and 20degrees/minute to 700° C. A purge of N₂ gas, at a rate of 10 cm³/minutewas used to sweep the evolved gases through the transfer line and theinfrared (IR) gas cell, both heated at a constant temperature of 240° C.Sixteen IR spectra (interferograms) of the evolved gases, at 4 cm-1resolution, were co-added at approximately 10 second intervals. A TE-TGSdetector was used for IR detection. The data showed an initial weightloss of about 0.24% due to water as the sample was initially heated.From about 105° C. into the isotherm at 150° C., a weight loss of 0.21%is seen due to the nitrogenous base. As the dispersion was heated to250° C., a weight loss of about 0.7% was seen due to carbon dioxide andpropionic acid, possibly mixed with an ester. A major weight loss of >5%was seen above 250° C. due to a mixture of carbon dioxide, carbonmonoxide, water, and what is likely cellulose acetate propionate.Overall, the resulting solid (silver nanoparticle composite) wasdetermined to contain 94.7% by weight of silver, about 0.3% by weight ofthe nitrogenous base and 5% by weight cellulose acetate propionate (seeFIG. 3).

Invention Example 3: Preparation of Non-Aqueous Dispersion of SilverNanoparticle-Cellulose Acetate Propionate Composite Using1,8-Diazabicyclo[5.4.0]undec-7-ene as the Nitrogenous Base

In a 2-necked round bottomed flask, a mixture of cellulose acetatepropionate (0.4 g; Eastman CAP 482-20, propionyl content 48%, Acetylcontent 1.3%, Mol. wt. of 75,000) and 1,8-diazabicyclo[5.4.0]undec-7-ene(16 g, mmol) in 2-methoxyethanol (28 ml) was heated at 95° C. withstirring until all cellulose acetate propionate was dissolved to form apremix solution. A solution of silver nitrate (8.8 g) dissolved in2-methoxyethanol (100 ml) was added to the premix solution over a periodof 80 minutes. The resulting reaction mixture was stirred at 95° C. foranother 20 minutes, cooled, and poured into water (800 ml). Theresulting precipitate was filtered and washed with methanol. A greycolored solid was obtained (yield of 98% based on silver). Particle sizedistribution was measured a dynamic light scattering method (MalvernInstruments Ltd. Zetasizer Nano-ZS (ZEN) Dynamic Light Scattering orQELS: Quasi-Elastic Light Scatter). The median particle diameter [Dv(50%)] was determined to be 350 nm. (see FIG. 4).

The gray colored silver nanoparticle composite (6 g) thus obtained wasadded to 1-methoxy-2-propanol (10 ml) and re-dispersed using a a highshear mixer (Silverson L4R) to obtain a non-aqueous silver-containingdispersion containing 60 weight % silver nanoparticle composite.

A pattern of lines of nominal width 2-20 mm was successfully formed fromthis non-aqueous silver-containing dispersion were on a poly(ethyleneterephthalate) film substrate using a flexographic test printer IGT F1and flexographic printing members obtained from commercially availableKodak Flexcel NX photopolymer plates that had been imaged using a maskthat was written using the Kodak Square Spot laser technology at aresolution of 12,800 dpi.

Invention Example 4: Preparation of Non-Aqueous Dispersion of SilverNanoparticle-Cellulose Acetate Propionate Composite Using4-Methylpyridine as the Nitrogeous Base

In a 2-necked round bottomed flask, a mixture of cellulose acetatepropionate (0.375 g; Aldrich, Mol. wt. of 50,000, Acetyl content 39%)and 2-methoxyethanol (7 ml) was heated at 85° C. with stirring until allcellulose acetate propionate was dissolved. A solution of silver nitrate(5 g) dissolved in 2-methoxyethanol (15 ml) was added into the reactionvessel and the resulting premix solution was stirred while being heatedat 85° C. The nitrogenous base 4-methylpyridine (1.5 g, mmol) was addedin portions and heating was continued of the resulting reaction mixturethat slowly turned yellow and then brown in color. Reaction wascontinued under heating at 85° C. for 20 hours and then the the heatedreaction mixture was poured into methanol (100 ml). The resultingprecipitate was filtered and washed with methanol to provide agrey-colored solid (yield 97% based on silver).

Particle size distribution was measured using a dynamic light scatteringmethod (Malvern Instruments Ltd. Zetasizer Nano-ZS (ZEN) Dynamic LightScattering or QELS: Quasi-Elastic Light Scatter). A median particlediameter [Dv (50%)] was determined to be 270 nm.

Invention Example 5: Preparation of Non-Aqueous Dispersion of SilverNanoparticle-Cellulose Acetate Propionate Composite Using Silver Acetate

In a two-necked round bottomed flask, cellulose acetate propionate (0.36g, mol. wt. of 15,000) was dissolved in 1-methoxy-2-propanol (19.0 g)with stirring at 95° C. Silver acetate (11.0 g) was then added to theflask to form a slurry or premix solution. A solution of2-(methylamino)ethanol (3.0 g) in 1-methoxy-2-propanol (4.5 ml) wasquickly added to the premix solution and heating was continued foranother sixty minutes. The resulting grey color slurry was poured into300 ml of water and the resulting precipitate was filtered and dried.

Particle size distribution was measured using a dynamic light scatteringmethod (Malvern Instruments Ltd. Zetasizer Nano-ZS (ZEN) Dynamic LightScattering or QELS: Quasi-Elastic Light Scatter). A median particle

Invention Example 6: Preparation of Non-Aqueous Dispersion of SilverNanoparticle-Ethyl Cellulose Composite

In a two-necked round bottomed flask, ethyl cellulose [0.42 g,Scientific Polymer Products Cat#463 ethyl cellulose (10 cps), ethoxylcontent 48%] was dissolved in 2-methoxyethanol (36.24 g) by stirring at80° C. for 30 minutes. 2-Methylamino ethanol (7.79 grams) was added tothe solution as a nitrogenous base to form a premix solution. A solutionof silver nitrate in 2-methoxyethanol (105 g, 8 weight % silver salt)was then added to the premix solution over two hours. Heating andstirring were continued for another thirty minutes. The resulting slurrywas poured into 800 ml water to form a precipitate that was filtered anddried.

ZEN Particle Sizing of another aliquot of the premix solution prior toprecipitation determined a silver nanoparticle composite particle sizedistribution having a mean size of 1200 nm. The resulting precipitatewas re-dispersed in 1-methoxy-2-propanol (50% solids) using a a highshear mixer (Silverson L4R) to obtain a printable non-aqueoussilver-containing dispersion.

The invention has been described in detail with particular reference tocertain preferred embodiments thereof, but it will be understood thatvariations and modifications can be effected within the spirit and scopeof the invention.

1. A method comprising, in sequence: A) mixing: (a) one or more polymersselected from one or more of cellulose acetate, cellulose acetatephthalate, cellulose acetate butyrate, cellulose acetate propionate,cellulose acetate trimellitate, hydroxypropylmethyl cellulose phthalate,methyl cellulose, ethyl cellulose, hydroxyethyl cellulose,hydroxypropylmethyl cellulose, and carboxymethyl cellulose; (b)reducible silver ions present in an amount of a weight ratio of (b)reducible silver ions to the one or more (a) polymers of at least 5:1and up to and including 50:1; and (c) one or more organic solvents, eachof which has a boiling point at atmospheric pressure of at least 100° C.and up to but less than 500° C., wherein the Hansen parameter (δ_(T)^(Polymer)) of each of the one or more polymers is less than or equal tothe Hansen parameter (δ_(T) ^(Solvent)) of each of the one or moreorganic solvents, to form a premix solution; B) heating the premixsolution to a temperature of at least 75° C.; C) while keeping thepremix solution at the temperature of at least 75° C., adding a (d)nitrogenous base having a pKa in acetonitrile of at least 15 and up toand including 25 at 25° C., to provide a concentration of the (d)nitrogenous base in an equimolar amount or in molar excess in relationto the amount of (b) reducible silver ions, to form a silvernanoparticle composite; D) after cooling, isolating the silvernanoparticle composite; and E) re-dispersing the silver nanoparticlecomposite in the same or different one or more (c) organic solvents usedin A), to provide a non-aqueous silver-containing dispersion comprisingthe silver nanoparticle composite.
 2. The method of claim 1, furthercomprising: disposing the non-aqueous silver-containing dispersion ontoa substrate, and removing the same or different one or more (c) organicsolvents.
 3. The method of claim 2, comprising disposing the non-aqueoussilver-containing dispersion onto the substrate in a patternwise manner.4. The method of claim 2, comprising disposing the non-aqueoussilver-containing dispersion onto the substrate using inkjet printing,screen printing, flexographic printing, or gravure printing.
 5. Themethod of claim 2, wherein the substrate has a first supporting side anda second opposing supporting side, and the method comprises disposingthe non-aqueous silver-containing dispersion onto the substrate in apatternwise manner to form at least one pattern of the non-aqueoussilver-containing dispersion on at least the first supporting side. 6.The method of claim 5, wherein the substrate is a continuous polymericfilm, and the method comprises disposing the non-aqueoussilver-containing dispersion onto the substrate in a manner to formmultiple patterns of the non-aqueous silver-containing dispersion on atleast the first supporting side.
 7. The method of claim 6, furthercomprising disposing the non-aqueous silver-containing dispersion ontothe substrate in a manner to form multiple patterns of the non-aqueoussilver-containing dispersion on the second opposing supporting side. 8.The method of claim 6, comprising disposing the non-aqueoussilver-containing dispersion onto the substrate to form multiplepatterns of the non-aqueous silver-containing composition on both thefirst supporting side and the second opposing supporting side using oneor more flexographic printing members.
 9. The method of claim 2, whereinthe substrate is a continuous web that is unrolled from a supply rolland is taken up using a take-up roll, and the method is carried out in acontinuous roll-to-roll manner.
 10. The method of claim 1, wherein thesilver is present in the non-aqueous silver-containing dispersion at aweight ratio to the one or more (a) polymers of at least 5:1 and up toand including 20:1.
 11. The method of claim 1, wherein the one or more(c) organic solvents is one or more hydroxylic organic solvents eachhaving an α-hydrogen atom and is chosen from the group consisting ofn-butanol, n-pentanol, n-hexanol, n-octanol, 2-ethyl-1-hexanol,n-decanol, ethylene glycol, propylene glycol, benzyl alcohol, isobutylalcohol, isoamyl alcohol, secondary butylcarbinol, secondary butylalcohol, secondary amyl alcohol, diethyl carbinol, methyl isobutylcarbinol, methyl-3-heptanol, diisobutyl carbinol, dodecanol-Z, methylallyl carbinol, cyclohexanol, methyl cyclohexyl carbinol, phenyl methylcarbinol, 2-methoxyethanol, 2-ethoxyethanol, diethylene glycol monoethylether, methoxy isopropanol, and a combination thereof.
 12. The method ofclaim 1, wherein the nitrogenous base is an aromatic cyclic compound.13. The method of claim 1, wherein the nitrogenous base is selected fromthe group consisting of 1,4-diazabicyclo[2.2.2]octane (DABCO),cyclohexylamine, piperidine, N-methyl pipperidine,N-methyl-3-piperidinol, ethanol amine, 2-(ethylamino)ethanol,2-(methylamino)ethanol, 2-(butylamino)ethanol, methyldiethanolamine(MDEA), diethanolamine (DEA), diglycolamine (DGA), diethylaminoethanol(DEAE), substituted or unsubstituted non-polymeric pyridine, picolines,lutidines, quinoline, purine, isoquinoline, imidazole, benzimidazole,benzthiazole, thiazole, oxazole, benzoxazole, 4,4′-bipyridine, pyrazine,triazine, pyrimidine, nicotinic acid, and isonicotinic acid compounds,1,8-diazabicyclo[5.4.0]undec-7-ene (DBU), and a combination thereof. 14.The method of claim 1, wherein the (a) one or more polymer is one ormore of carboxymethyl cellulose, cellulose acetate butyrate, ethylcellulose, cellulose acetate, and cellulose acetate propionate.
 15. Themethod of claim 1, wherein the non-aqueous silver-containing dispersionfurther contains (e) a carbon black.
 16. The method of claim 1, whereinthe non-aqueous silver-containing dispersion has a viscosity of at least1 centipoise (0.001 Pascal sec) and up to and including 5000 centipoise(5 Pascal sec) at 25° C.
 17. The method of claim 1, wherein thenon-aqueous silver-containing dispersion has a viscosity of at least 3centipoise (0.003 Pascal sec) and up to and including 10 centipoise(0.01 Pascal sec) at 25° C.